Rake for self-cleaning pet litter apparatus

ABSTRACT

A rake for a cat litter box for collecting clumped litter waste material from within the cat litter box includes a support member. A plurality of tines are connected to the support member. Each of the plurality of tines includes a first section connected to and extending from the support member. Each of the plurality of tines further includes a second section extending generally perpendicularly to the first section. The second section of the tines receives the clumped litter waste material in a receiving area. At least one of the plurality of tines second sections includes an upwardly curved portion, curved toward the support member for defining multiple regions of the tines within the receiving area, such that the clumped litter waste material is contained in the multiple regions when collected from the cat litter box.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 10/967,613 filed Oct. 18, 2004 now U.S. Pat. No. 7,017,519 andentitled “Self-Cleaning Pet Litter Apparatus and Related Method.”

TECHNICAL FIELD

The present invention pertains to litter boxes for use by animals,typically cats. More particularly, this invention is directed towardapparatus which operates in a self-cleaning fashion, eitherautomatically or manually, to remove waste materials deposited in thelitter, thereby obviating the need for frequent and periodic service bythe animal's owner.

BACKGROUND OF THE INVENTION

Domestic pets, particularly cats, typically utilize a litter box fortheir waste needs. Such litter boxes fall into two categories, thetotally manual pan or container which carries a quantity of litter andthe automatic or self-cleaning variety, which also carries a quantity oflitter. The present invention pertains to the latter category and thepatent literature does include a variety of such devices. U.S. Pat. No.6,568,348, for instance, is directed to a circular litter device thatextracts waste from litter material by rotating a rake or the chamber.Due to rotation of the rake or chamber, solid waste is extracted fromthe litter material using tines, and such waste is pushed to the outerperimeter of the chamber. The curvature of the rake allows the rake tocooperate with a scoop, which simultaneously removes solid waste fromthe rake and retracts into a tunnel, as the rake passes thereby.

U.S. Pat. Nos. 6,401,661 and 6,234,112 are both directed to a selfcleaning pet litter box. The pet litter container is rotatably mountedon a base member, and rotates to move the pet litter over a sieve. Thesieve is ramped shaped and therefore, clumped portions of the pet litterthat are not sifted through its openings are forced upwardly toward aconveyer. The conveyer serves to carry the clumped portions of petlitter away from the pet litter container.

U.S. Pat. No. 6,286,459 is directed to a litter container with a rotarymovement sieve. The sieve is attached to a rotatable ring around theupper portion of a container. As the sieve rotates, clumped portions ofsolid waste are captured thereon. Since the sieve is removable, thesieve, and the clumped portions of solid waste can be removed from thecontainer.

U.S. Pat. Nos. 6,082,302 and 5,447,812, are both directed to arectangular litter device that extracts waste from litter material usinga comb that traverses the pan lengthwise, eventually conveying wasteclumps into a receptacle at the front of the device.

U.S. Pat. No. 4,574,735 is directed to a circular litter device thatextracts waste from litter material using a rake which sweeps through acircular chamber. In this device, the waste material is deposited into acontainer which is rotated to sanitize and deodorize the contents.

The foregoing automatic litter devices have provided a variety of stylesand mechanisms to facilitate periodic cleaning of the litter.Nonetheless, the apparatus of the present invention provides a novelapproach to the design and operation of such devices by providing asingle drive mechanism for the operation of all moving elements as wellas other features not present in combination in a single deviceheretofore.

SUMMARY OF THE INVENTION

In accordance with the present invention, a rake for a cat litter boxfor collecting clumped litter waste material from within the cat litterbox is provided. The rake includes a support member. A plurality oftines are connected to the support member. Each of the plurality oftines includes a first section connected to and extending from thesupport member. Each of the plurality of tines further includes a secondsection extending generally perpendicularly to the first section. Thesecond section of the tines receives the clumped litter waste materialin a receiving area. At least one of the plurality of tines secondsections includes an upwardly curved portion, curved toward the supportmember for defining multiple regions of the tines within the receivingarea, such that the clumped litter waste material is contained in themultiple regions when collected from the cat litter box.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view depicting the self-cleaning litter apparatusof the present invention;

FIG. 2 is an exploded isometric view of the self-cleaning litterapparatus of the present invention;

FIG. 3 is an isometric view depicting the underside of the self-cleaninglitter apparatus of the present invention;

FIG. 4 is an isometric view depicting the underside of the litter pan;

FIG. 5 is a partial isometric view depicting the turntable of theself-cleaning litter apparatus;

FIG. 6 is an isometric view depicting the underside of the turntable;

FIG. 7 is a partial isometric view depicting the base of theself-cleaning litter apparatus and related components for driving theturntable;

FIG. 8 is a side elevation of a weight sensor, depicted over the contactrails carried in the base;

FIG. 9 is an isometric view of a weight sensor, depicted over thecontact rails carried in the base;

FIG. 10 is another isometric view depicting the underside of theturntable and the drive mechanism, with portions of the apparatusremoved for clarity;

FIG. 11 is a cross-sectional view of the apparatus, depicting the base,turntable, litter pan and rake assembly;

FIG. 11A is an enlarged cross-section of the area 11A, depicted in FIG.11;

FIG. 11B is an enlarged cross-section of the area 11B, depicted in FIG.11;

FIG. 11C is an enlarged cross-section of the area 11C, depicted in FIG.11;

FIGS. 12–16 are isometric views of the litter apparatus of the presentinvention, depicting the rake sequentially moving from rest, through thelitter pan, out of the litter pan and depositing waste litter materialinto the receptacle;

FIG. 17 is a partial isometric view, depicting the rake assembly;

FIG. 18 is a partial isometric view, looking from the front of theapparatus, depicting the rake assembly in relation to the cam member forrotation of the rake;

FIG. 19 is a partial isometric view, looking down and from the rear sideof the apparatus, depicting the rake assembly in relation to the cammembers for rotation of the rake and lifting the cover on thereceptacle;

FIG. 20 is a partial isometric view, similar to FIG. 18, with componentsremoved to reveal the drive mechanism and the rake assembly;

FIG. 21 is a side elevation of the rake assembly, separately from theapparatus and the drive mechanism positioned beneath the base;

FIG. 22 is a partial isometric view, looking down and from the rear sideof the apparatus, depicting the rake assembly and the rake at rest;

FIG. 23 is a partial isometric view, looking down and from the rear sideof the apparatus, depicting the rake assembly and the rake at rest;

FIG. 24 is a partial isometric view, looking from the rear side of theapparatus, depicting the rake assembly and rake at rest with thereceptacle cover closed;

FIG. 25 is a partial isometric view, similar to FIG. 24, with thereceptacle cover opening for receipt of litter waste;

FIG. 26 is a block diagram of the control and sensors for the litterapparatus; and

FIG. 27 is a block diagram of the weight sensing mechanism;

FIG. 28 is a top, left perspective view of the present rake;

FIG. 29 is a top, plan view of the rake shown in FIG. 28;

FIG. 30 is a top, right perspective view of the present rake; and

FIG. 31 is a sectional view taken along section lines 31—31 of FIG. 29.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1 and 2, a self-cleaning litter apparatusaccording to the present invention, is depicted generally by the numeral30. It includes a main base, generally 31, which carries a turntable,generally 32, a litter pan, generally 33, received onto the turntable, ashield 34, a hood 35, a rake assembly, indicated generally by thenumeral 36, a waste receptacle 37, a housing 38 for the drive mechanism,which will be described subsequently and a ramp 39, which may optionallyprovide a mat 40, for the purpose of cleaning litter from the pet uponexiting the apparatus. Of these components, the hood 35 and the ramp 39are both optional, as the self-cleaning features of the apparatus do notrequire the presence of either component. In order to aid inmanufacturing, while providing strength and reasonable cost, the variouscomponents are manufactured from a conventional thermoplastic, such asABS or a polyolefin, such as polyethylene or polypropylene. Othercomponents, such as the internal gears can be manufactured from nylon.

The hood 35 provides a domed top 41 which terminates in an outwardlyextending annular flange 42. A recess 43 is provided in the top 41 forreceipt of an air filter element 44, which is removable from theunderside of the hood. A handle 45, is molded into the top over therecess. The front of the hood 35 provides an opening 46, through whichthe cat, or other domestic pet, enters and leaves the litter apparatus.

The shield 34 is removable, lifting off of the litter pan 33, when thelatter is to be cleaned. It comprises a truncated annular flange, theouter wall 47 of which frictionally engages the inner wall 48 of thehood 35. The outer wall 47 is recessed, to provide an opening 49,extending across less than one-half of the front of shield 35, to allowfor movement of the rake assembly 36, as will be described later.

The litter pan 33 includes a body 50 having a circular base 51, acontinuous upwardly extending sidewall 52, terminating in an outwardlyextending annular flange 53. In FIG. 7, the bottom of pan of 33 isdepicted, showing the underside 54 of base 51. Underside 54 provides aseveral projections at various positions. A coupling, generally 55, iscentrally located and includes a ring 56 encompassing a recess 58, forreceipt of a hub-spindle assembly, generally 59, carried centrally ofthe turntable 32. Radiating outwardly from the ring 56 are a pluralityof fins 60, which mate with the spindle, as will be described in greaterdetail below, so that as the turntable 32 is rotated, the litter pan 33is likewise rotated.

Radially outwardly of the coupling 55 are a plurality of feet 61, whichare received in foot wells 62, provided in the floor 63 of the turntable32 (FIG. 5). Radially outwardly of the feet 61 are a plurality ofbuttons 65, which engage weight sensors, generally 66, which are carriedby the turntable 32.

The turntable 32 is depicted in FIGS. 5, 6, and 10 to which referenceshould be made next. Beginning with FIGS. 5 and 6, the turntable isgenerally dish shaped and has a raised central floor 63 which extendsover a major portion of the diameter. It terminates with downwardsidewall, which forms the inner wall 70 of an annular trough 71, beneaththe floor. The trough continues to an outer wall 72, which extendsupwardly to join an outer rim 73, slightly lower than the floor 63. Anouter ring wall 74 extends upwardly from the rim 73, terminating in anupper face 75 and upstanding peripheral rim 76. On the outside of outerring wall 74, a ring gear 78 is formed, which allows the turntable to berotated.

In FIG. 6, the turntable is viewed from its underside, where it can beseen that the trough 71 has a plurality of discontinuities, eachextending partially upwardly within the trough providing platforms 80,each carrying a weight sensor 66. As depicted in the drawing, six suchplatforms 80 are shown, although the turntable could be modified toprovide more or less than six so long as a sufficient number are presentto sense the weight of an animal in the litter pan, which will beexplained hereinbelow. Returning to FIG. 5 and the upper side ofturntable 32, the foot wells 62 in central floor 63 are coplanar withthe trough 71 and are bounded by leading and trailing ramps, 81, 82,which help orient the placement of the litter pan 33 and engagement ofthe feet 61 in the wells 62.

At the center of the turntable, is the hub-spindle assembly 59,comprising a hub 85 and a spindle 86. The hub 85 is a small diameter cupwhich extends from and below the turntable floor 63 and terminates in araised shelf 88, also beneath the plane of the floor 63. The spindle 86,depicted in FIG. 11B, provides two intersecting semi-elliptical members89 which terminate in a rounded end upon which the recess 58 in thecoupling member 55 of litter pan 33 rests, so as to be tiltablyrotatable thereon. The members 89 are carried by a platform 90 andextending downwardly therefrom are four fingers 91 disposed at 90°angles from each other. The spindle fingers 91 are snapped into an openbase hub 92, formed in the floor 93 of main base 31 (see FIG. 3).

The fingers 91 have outwardly extending flanges 94, which lock againstthe bottom edge 95 of base hub 92. As also shown in FIG. 11B, a screw96, carrying a spacer 98 is driven into the central body 99 of spindle86, which urges the fingers 91 into engagement with the base hub 92. Inthis manner the turntable 32 is fastened to the base and can likewise bedisassembled by first removing the screw 96. To aid rotation of theturntable 32 over the base hub 92 of the base 31, a washer 100 isinterposed.

The floor 93 of main base 31 is partially depicted in FIG. 7 and incross-section in FIG. 11, to which reference should be made next.Generally, the floor 93 is molded to allow for the turntable 32 torotate freely therein, the latter having been mounted therein aspreviously described. In addition, the base also provides two othermechanisms—one to assist rotation of the turntable and one that works aspart of the weight sensing mechanism, which will be describedsubsequently. The base has an exterior wall 103, for appearance andenclosing the drive mechanism.

As clearly depicted in FIGS. 7 and 11A, the floor 93 of main base 31carries an annular trough 104, near its periphery. Radially outwardlyfrom the trough 104 is a raised shelf 105, which extends to the innerwall 106 of base 31. A plurality of wheels 108 are fit into recesses 109in shelf 105, each said wheel being rotatably mounted about an axle 110,pressed into a mating well 111 carried in the underside of shelf 105.The wheels 108 protrude outwardly from the shelf 105, as depicted inFIG. 7, where they will periodically engage the outer edge 112 ofannular trough 71 (see the underside of turntable 32) to keep itcentered and supported about the spindle 86. The number of wheels is notcrucial to the operation of the apparatus, so long as they are equallyspaced about the circumference. Typically, four wheels are adequate.

A like plurality of rollers 113 are carried in semi-cylindrical recesses114, in the shelf 105. The rollers reduce friction between the turntable32 and main base 31 as the turntable is rotated therein. The combinedsupport and centering can be seen schematically in FIG. 10, where themain base has been removed from view, leaving the rollers 113 and wheels108 in place against the underside of turntable 32. Again, the number ofrollers 113 is not crucial to the operation of the apparatus, so long asthey are equally spaced about the circumference. Typically, eightrollers are adequate. Together, the rollers and wheels provide asupporting and centering mechanism, indicated generally by the numeral115, for the turntable 32.

The weight sensing mechanism is indicated generally by the numeral 120and it includes the weight sensors 66 and a track assembly, generally121. Referring to FIG. 7, the track assembly comprises a pair ofelectrically conductive outer and inner rails 122, 123, respectively.The rails are mounted in the annular trough 104, which is formed into araised shelf 125, and extends upwardly from the floor 93 of the base 31.Spacers 126, made from plastic or other non-conductive material, arelocated periodically around the shelf 125 in a number sufficient tomaintain the rails parallel to each other. The spacers are suitablyfastened within the trough 104 by screws, not shown, passing thoughapertures 128 and their width forces the opposed rails against the wallsof the trough so as to remain immovable therein. An end of the outerrail 122 is bent and passes through an aperture 130 in the base to theunderside and is connected electrically to a power source (not shown).The opposite end of rail 122 is brought around the trough 104 and intocontact with the beginning end. In similar fashion, an end of the innerrail 123 is bent and passes to a shield 131, where a wire (not shown) isconnected, fed around tab 132 and through aperture 133 in the base tothe underside for connection to the power source. The opposite end ofrail 123 is brought around the trough 104 and into contact with thebeginning end.

The weight sensors 66 are depicted in FIGS. 8 and 9. Each sensorcomprises a body 135, an opposed set of conductive spring feet 136, 138and a compression spring 139. The body, in turn, is formed of twopieces, a head 140, having a square shaft 141, extending downwardlytherefrom, and a T-shaped base 142, also square and which terminates ina cross-wise foot 143 (see FIG. 11A). The T-shaped base 142 is assembledfrom beneath the turntable 32, though a square aperture 144 (FIG. 6) andthe head 140 is positioned from above the turntable after firstinstalling the compression spring 139 about the shaft 141. The shaft 141is fit within an accommodating passage formed in the base 142. Finally,the spring feet 136, 138 are connected by way of a flat shoe 145, ofplastic or similar material, with a screw 146 which joins the shoe 145to the base 142 and finally to the shaft 141. The shoe 145 is wider thanthe aperture 144 and prevents the sensor 66 from being removed from theturntable 32.

Two installed sensors 66 are depicted in FIG. 5, each being positionedon a platform 148 raised up within the trough 71. With reference toFIGS. 11C and 11A, the turntable 32 is presented, in cross-section,resting upon the rollers 113 and centered among the wheels 108. Thebuttons 65, carried on the underside of the litter pan 33 are depictedin contact with the head 140 from a sensor 66. In the positions shownthe two make contact, however, the head has not been forced down, whichwould result in the spring feet 136, 138 contacting the rails 122, 123.When the apparatus 30 is not occupied by an animal, this is the normalor operational condition. The pan is balanced on the spindle 86, aspreviously described and is either stationary, or rotating duringself-cleaning. Typically, a cleaning cycle is activated automaticallyafter the expiration of a pre-set time, for instance, 30 minutesfollowing the last activity in the apparatus. This ensures first thatthe pet has not decided to return and second, that the self-clumpinglitter has adequate time to solidify liquid waste, so that it can bereadily removed from the litter as a solid mass.

At such time, the drive mechanism will be activated to clean the litter,as will be described hereinbelow. In operation, the weight of the animalin the pan is sufficient to cause it to tilt slightly about the spindle86, e.g., approximately 2°, which causes one of the buttons 65 to engagean opposed head from sensor 66. If the buttons 65 are not employed onthe pan 33, the pan may be required to tilt a little more until theunderside of the pan is brought into contact with the head of a sensor66. Contact with the head 140 causes the feet to make contact with therails which sends a signal to a controller.

With reference to FIG. 7, the inner wall 106 of base 31 is shown, as isa port 150, through which a drive gear 151 partially extends, sufficientto engage ring gear 78 from the turntable 32 and thereby cause rotationof the turntable and litter pan 33, carried thereon. The drive mechanismwill be described subsequently but at this point it is sufficient tonote that when gear 151 is rotated counter clockwise, when viewed fromabove, the turntable will rotate in a clockwise direction, which beginsand continues during a self-cleaning cycle. Concurrent with suchrotation of the litter pan 33, the rake assembly 36 is driven in aclockwise direction through the litter in the rotating pan andeventually to deposit waste material into the waste receptacle of theapparatus, indicated generally by the numeral 37. The receptacleprovides a separate container 153, having a floor 154 and a hinged door155, which is automatically opened during a self-cleaning cycle.

With reference next to FIGS. 1 and 12–16, the operation of the apparatusduring a self-cleaning cycle will be discussed. For the sake of clarityno litter has been depicted in the litter pan 33. As is common inself-cleaning litter apparatus, a self-clumping litter is recommendedand it operates by clumping liquid waste, e.g., urine, into a singlemass, which can then be scooped away, much the same as solid waste. InFIGS. 1 and 12, the apparatus 30 is at rest. In this position, the tinesfrom the rake 160 are almost contacting the bottom 51 of litter pan 33,where they are submerged in the litter to scoop beneath any clumps ofwaste material.

As the apparatus is cycled, which can either be controlled to operateautomatically within a pre-set time of non-activity by the pet or, uponactivation manually by the pet owner, the pan 33 is moving in itsclockwise rotation and the rake assembly 36 is also moving in aclockwise fashion, arcuately across and through the pan. The assembly 36moves from a rest or parked position, against the inner wall 161 of theshield 34, near the opening 48, proceeding in a countercurrent fashionthrough the litter, as depicted in FIG. 13. In FIGS. 12–16, the door 155has been removed for clarity and a door pusher 162 is shown. Itsmovement will be described subsequently. In FIGS. 12 and 13, the doorpusher has not begun to move and thus, the door 155 remains closed. InFIG. 14, as the rake assembly 36 continues its sweep through the litter,the door pusher 162 has begun upward movement, that is, it rotates fromthe entrance side 163 of the container, adjacent the shield 34, towardthe opposite, hinged side 164 of the container. As this occurs, the door155 (not shown) which rests on the pusher is likewise beginning to lift,opening the receptacle.

In FIG. 15, the rake 160 has lifted out of the litter pan 33 and hasrotated upon its axis to hold waste clumps within the rake 160 and doorpusher 162 has moved further upwardly. Finally, in FIG. 16, the rake hasfirst moved directly over the receptacle 37 and then rotated all the wayupon its axis, allowing gravity to free the waste and waste clumps fromthe tines and fall into the open container 153. The door pusher 162 isin its highest position and the door 155 will be completely open. At theend of this forward or first part of the cycle, the motor driving themechanism is reversed, causing the retraction of the rake back into thelitter pan, beneath the litter to its original resting position. Whilethis reversal of the rake proceeds, the turntable is also reversed, torotate counter-clockwise as the rake 160 moves downwardly through thelitter and the door 155 is allowed to close.

While the foregoing explanation has referred to rotations in clockwiseand counter-clockwise directions, such orientations are only applicableto the apparatus as shown in the drawings. Accordingly, it is to beunderstood that the specific directions of rotation do not constitutelimitations on the practice of the present invention, as it will beappreciated that an apparatus manufactured as a mirror image of theapparatus 30, would operate in the opposite directions, as the pan andrake moved first from the parked position and later returned to theparked position.

In order to ensure that waste and waste clumps are driven toward thetines, several stationary tines 165 are provided from an extension 166provided radially inwardly from the opening 148 in the shield. As thepan 33 rotates, any clumps that were deposited or formed near the innerwall 168 of the pan will, upon rotation in clockwise fashion, be drivenradially inwardly upon contacting the stationary tines 165, where theywill be in a path to be scooped away by the rake assembly 36. As willbecome apparent subsequently, the turntable and pan rotate at asignificantly higher rpm than the counter rotation of the rake assembly.In this manner, essentially all of the waste material is driven into thepath of the oncoming rake assembly before it actually makes its completepass through the litter. Generally, it is preferred to have the panrotate at approximately three and one-half times the arcuate rotation ofthe rake assembly 36, although ratios greater than or less than 3.5:1are not necessarily precluded. What is important is that the ratio behigh enough so that all or most of the waste material meets with therake for removal from the pan.

Next, the rake assembly shall be described with specific reference toFIG. 21, which depicts a skeletonized structure of the rake assembly 36,which resides on the upper side of the apparatus 30 and the drivemechanism, indicated generally by the numeral 170, which is housed inthe main base, more particularly, in the drive housing, indicated by thenumeral 38. To protect the pet as well as the owner, the moving parts ofthe drive mechanism are located in the lower, inside portion of the mainbase, as depicted in FIG. 20, where the various components of theapparatus have been removed to reveal the relationship between theassembly 36 and mechanism 170.

The rake assembly 36 provides a central steel shaft 172, hexagonal incross-section for the various components it carries. Beginning at theleft end, as viewed in FIG. 21, the rake holder 173 is attached, whichcarries the rake 160, discussed hereinabove. The rake holder issemi-arcuate, of a lesser diameter than the shield 34, in order to fitclosely to the inside wall 161 when the rake holder is in its parked orrest position. The tines of rake 160 are affixed to the underside of theholder and project straight down to almost the face 51 of litter pan 33where they are then bent forward, parallel to the pan to form a flatscoop 174 (see FIG. 25). Several lateral tines 175 are affixed to theoutermost end tine, to prevent waste materials from falling off the endof the scoop. The rake holder 173 is firmly joined to the shaft 172,with the rake lock 176. The rake holder can provide a bayonette-type offitting to the shaft so that twisting the rake lock one-half turn willrelease the rake holder from the shaft for cleaning purposes as well asdisassembly of the basic components of the apparatus.

The next component on the shaft is a small wheel 178, which is held inplace with an e-ring 179. Adjacent the wheel is a small cam 180,followed next by the upper main driving shaft 181. A torsion spring 182encircles the shaft 172 next and its two legs (not shown) are connected,one into the back of upper main driving shaft 181 and the other into ahole in shaft 172, biasing the shaft to rotate in clockwise fashion, asviewed in FIG. 21. Immediately adjacent the spring 182 is another e-ring183, which holds a large wheel 184 in place on the shaft and at the farend of the shaft, is a key cam wheel 185.

The upper main driving shaft 181 has a circular plate 190 at itsmidsection and a cylindrical base 191, into which a vertical,hexagonally-shaped steel shaft 192 is located. The base member 191passes through an aperture in rake assembly base 193, as depicted inFIG. 19, the circular plate 190 providing a bearing surface for therotation of upper main drive shaft 181 and related components upon therake assembly base. The rake assembly base, in turn, is fastened to theupper floor 194 in drive housing 38 (see FIG. 22) and is accessible whenthe cover 195 (FIG. 1) is unfastened from housing 38. Beneath the rakeassembly base and the floor 194, the lower main driving shaft 196 isattached to the steel shaft 192, which is visible in FIG. 23, where thefloor 194 has been removed.

Returning to FIG. 21, the drive mechanism 170 provides a series ofintermeshing gears as follows. Gear 151, at the far left of the drawingis the gear that drives ring gear 78 beneath the turntable 32. Meshingwith it are gears 200 and 201, journalled to the same shaft 202. Gear201 meshes with upper drive gear 203, which is driven by a motor 204,which is affixed to a mount 205, provided on upper gear housing 206,depicted in FIG. 25. A suitable motor is of the type usually found incordless screw drivers, which are 12 volt, and run at approximately10,000 to 12,000 rpm. A current source of such motors is Mabuchi or GoldEffort. Of course, other motors can be employed and may require adifferent ratio of gears. The motor is powered by a conventional 12 volttransformer and a power output jack can be plugged into a suitablereceptacle, provided on the exterior of the main base 31, as at 199 (seeFIGS. 22 and 25). As such means are well understood in the art, thetransformer and related wiring necessary to operate the apparatus 30have neither been depicted nor, described herein. Of course, theapparatus 30 could be provided with a battery compartment and battery,as an alternative source of power. Such devices are well known in theart and have not been depicted herein.

Beneath upper drive gear 203 is lower drive gear 207 and beneath gear207 is a bushing 208. Lower drive gear 207 meshes with gear 209,journalled on shaft 210 and carrying gear 211. Gear 211 meshes with gear212. Immediately above gear 212 is a small gear 213, then a large gear214, and another small gear 215 all four being journalled on shaft 216.Large gear 214 meshes with gear 218, which drives the shaft 192 torotate the rake assembly 36. Gear 213, in turn, meshes with gear 219,behind it and another small gear 220 is located above 219, both beingjournalled on a shaft 221, visible in FIG. 20. As will become apparent,the apparatus 30 operates from a single motor, as part of the drivemechanism 170, which concurrently rotates the pan 33, rotates the rakeassembly and opens the cover 155 of waste receptacle 37. As viewed inFIG. 20, the various gears are mounted on a lower gear housing 222,itself mounted to the floor 223 of a lower compartment 224, which ishoused within the main base 31, next to the waste receptacle 37.

In FIG. 17, the inboard and outboard side walls 228, 229, extending upfrom the drive housing 38 and surrounding around the floor 193, definean upper compartment, generally 230. Two removable gate guilders, 231and 232 are provided at the front of the compartment 230. The guilder232 is shown in FIG. 17 and provides a slot 234, to accommodate thesmall wheel 178 of assembly 36. A curvilinear front wall 235 ofcompartment 230, slightly lower than side walls 228, 229, provides anupper edge 236 along which the wheel 178 rolls. Inside of the front wall235 are a series of vertical tabs 238 which follow the curvilinearcontour of the wall, leaving a narrow channel 239, as depicted in FIG.18, into which a flexible shield member 240 is positioned (see FIG. 22).

The shield 240 can be a length of clear plastic material and is providedwith a hole 241 of sufficient diameter to receive the wheel 178 of rakeassembly 36. Although not shown in the drawings, the cover 195 alsoprovides a continuous sidewall which mates with the sidewalls 228, 229.The front portion of the sidewall of cover 195 is also curvilinear andthe cover provides another series of tabs, similar to the tabs 238, andanother channel is formed. When fully assembled, the shield member 240is positioned between the two channels and slides therein as the rakeassembly traverses from the parked position in the litter pan to thedumping position over the waste receptacle. Its purpose is to minimizethe entrance of dust or litter grains from the litter pan into thecompartment 230.

Referring now to FIGS. 17 and 22, adjacent the rake assembly base 193, aarcuate platform 245 is provided on the floor 194 of compartment 230.The arc traversed is approximately 90° and the platform is raisedsufficiently to contact the large wheel 184 of rake assembly 36 in orderto provide support for the rake holder 173 as it traverses the litter,carrying waste material. Behind platform 245 a second platform 246 isprovided, higher than platform 245. Unlike the former, which has only aflat upper surface, the platform 246 has a generally flat upper surface,transitioning to a downward ramp 248 which curves toward and joins thefloor 194. A third platform 249 is provided on the rake assembly base193, in front of the first platform 245. Platform 249 has a ramped uppersurface which begins at the rake assembly base and rises toapproximately the height of the first platform 245. It is, however,considerably shorter in length than the first two platforms.

The key cam wheel 185 at the opposite end of rake holder 173 has arounded top and flat underside 250 which rides along the surface of thesecond platform 246. Extending downwardly from the underside 250 is acam 251, which is engageable with a step 252, along side of and integralwith the second platform 246. As the rake holder 173 begins its sweepacross the litter pan, an edge of the underside 250 from cam wheel 185is passed along the horizontal surface of platform 246, moving from therest position, depicted in FIG. 12. Just prior to the position depictedin FIG. 13, the cam 251 begins to contact the step 252, which starts anupward rotation of the rake holder 173, into a waste holding position.At this point, a minor rotation of the main driving shaft 181 occurs sothat the opposite edge of the underside 250 from cam wheel 185 contactsthe horizontal surface of platform 246. With the rotation of the rakeholder 173, it is elevated out of the pan 33, to clear the shield 34 andeventually empty its contents into the waste receptacle 37, as depictedin FIGS. 14–16. Along the way, the cam wheel 185 is freed from theplatform 246. Toward the end of the forward cycle, the small cam 180makes contact with the third platform 249. As the cam 180 follows theramp on platform 249, it is rotated which, in turn, rotates the rakeholder 173 in a counter-clockwise direction, as viewed from the distalend, so that the contents carried by the scoop 175 are emptied into thewaste receptacle 37, as depicted schematically in FIG. 16.

For the return cycle, the drive mechanism 170 is reversed, causing therake holder 173 to move out of the waste receptacle toward a position ofrest in the litter pan. Initial movement rotates the rake holder 173sufficiently to clear the receptacle as the cam 180 retraces itsmovement over the third platform 249. Continued rotation of the uppermain driving shaft 181 causes the cam 251 to engage the second platform246, whereby the rake holder 173 is again returned to its leveled, orscooping position in the litter contained in the pan 33. The torsionspring 182 assists here, biasing the rake holder 173 counter-clockwiseso that the flat scoop 174 is driven into the litter. Thereafter, thedriving shaft 181 concludes its rotation until the rake holder 173 isparked in its initial rest position.

The floor 194 and sidewall 229 of drive housing 38 are removable as aunit and together house a lower compartment, generally 256, of the base31. Behind the second platform 246 is a small compartment 258, whichreceives a controller 259 for operation of the apparatus 30. Thecompartment 258 extends into the lower compartment and provides a slotholder 260, housed within the base 31. A control button 261 is providedfor manual operation of the apparatus. One embodiment of apparatus isfully self-cleaning, by which is meant that the cleaning cycle beingdescribed occurs without intervention by the pet owner. Nonetheless,should the pet owner wish to initiate a cycle, the power button 261 canbe activated. The apparatus 30 can also be manufactured as a manual dutydevice, in which instance, the circuit board is not programmed toinitiate a self-cleaning cycle automatically but rather the pet ownercan do so upon demand. It is to be understood that while a button isdepicted, the apparatus could also be provided with a foot controlswitch or a remote switch. Other means of automatic activation could beinitiated from a micro-chip, embedded in the collar worn by the pet.None of the foregoing devices are depicted or described, as they arewell known in the art.

With reference to FIG. 19, the lower compartment 256 is exposed andreference should be made to the lower main driving shaft 196. It is tobe appreciated that several upper components have been removed to revealelements in the lower compartment 256 and in so doing, several of theremaining elements depicted appear to be floating. At the lower end ofbase 196, an inwardly directed link arm 264 extends radially out and anoutwardly directed cam 265 extends radially out, approximately 165° fromthe link arm. The cam 265 is engage able with opposed inboard andoutboard limit switches, 266 and 268, respectively. Both switches aremounted to struts, not shown, that are provided in the underside of thefloor 194, which has been removed. The inboard switch 266 functions toreverse the cleaning of the pan (FIG. 16) so that the rake assembly 36returns to its parked position (FIG. 12). The outboard switch 268signals the apparatus to stop movement, until the next cleaning cycle isto be activated.

With reference next to FIGS. 10 and 24, the mechanism for opening thewaste receptacle, which is indicated generally by the numeral 270, willbe described. It includes a link arm 271, a lever 272, and the doorpusher 162, described previously. These work in conjunction with theinwardly directed link arm 264. One end of the link arm 271 is pivotallyconnected to the inwardly directed link arm 264, at 273. The other endis connected to the lever 272 at 274, and the lever 272 is itselfpivotally connected at 275 to the underside of the floor 194.

As the inwardly directed link arm 264 is rotated during the forwardmovement (cleaning) of an operation cycle, the link arm 271 urges thelever 272 to move rearwardly, as viewed in FIG. 25. A cam 276, providedby the lever 272 engages the underside of door pusher 162, which beginsto rise. The pusher 162 is pivotally mounted to a wall 278 of the wastereceptacle 37 at 279. In FIG. 25, the engagement of the door pusher 162with the waste receptacle cover 155, as it is being lifted, is depicted.The various stages of upward movement of the door pusher 162 are alsoapparent in the sequential views, FIGS. 12–16, described hereinabove,where the cover had been removed for clarity.

Referring now to FIGS. 28–31, the rake of the present invention isillustrated, and is generally identified by the numeral 360. Rake 360operates in a manner similar to rake 36; previously described withrespect to FIGS. 1–27. Rake 360 includes a support member 362 from whicha plurality of tines, generally identified by the numeral 364, areconnected to and extend from.

Each of the plurality of tines 364 includes a first section 366 whichare connected to and extend from support member 362. Tines 364 furtherinclude a second section 368 which extend generally perpendicular tofirst section 366 of tines 364.

First sections 366 of tines 364 are interconnected and supported by ribs370 and 372.

Second sections 368 of tines 364 create a clumped litter waste materialreceiving area, generally identified by the numeral 374. Second sections368 of tines 364 generally lie in a common plane in receiving area 374.

At least one of second sections 368 of tines 364, shown in FIGS. 28–31as second section 376 includes a upwardly curved portion 378. Upwardlycurved portion 378 curves upwardly towards support member 362, and isformed by a bend in one of second sections 368. Upwardly curved portion378 defines multiple regions, 374 a and 374 b of second sections 368within receiving area 374. In this manner, clumped litter waste materialfrom the litter pan 33 is constrained within multiple regions 374 a and374 b as rake 360 deposits waste material into waste receptacle 37 (FIG.1). The weight of the waste material is therefore evenly distributedover tines 364 while the waste material is being transported from thelitter pan 33 to the waste receptacle 37.

Rake 360 further includes constraining members 380 and 382 for retainingclumped litter waste material within region 374 a as rake 360 transportswaste material from the litter pan 33 to the waste box 37.

General Operation

Having described the components of the apparatus 30, a generaldiscussion of the self-cleaning cycle follows. Normally, the apparatusis at rest, which occurs whenever the apparatus has been filled withlitter, turned on and is awaiting use by the pet. When the pet entersthe apparatus, beginning at the ramp 39 and entering into the litter pan33, the weight of the animal depresses the turntable 32, so that one ofthe weight sensors 66 makes contact with the rails 122, 123. In otherwords, the weight sensing mechanism 120; which comprises the weightsensors and the track assembly 121, is provided for the actuation of apetinitiated cleaning cycle. The controller is preferably programmed tosignal the timer after the weight of the animal has engaged a weightsensor with the rails for a minimum of 3 to 5 seconds. In other words, abrief contact between the sensor and rails will not cause a cycle to beinitiated, because the pet would not have used the litter box. After theanimal concludes its business and exits the apparatus, the turntable isagain fully righted upon the spindle 86 and a signal is generated to thecontroller 259 to begin activation of a cleaning cycle, within apre-determined time. Recognizing that the pet may return, a sufficientperiod is usually 30 minutes. Additionally, the apparatus employsself-clumping litter, which requires several minutes to absorb liquidwaste and form a solid having sufficient integrity to be moved. Oncebegun, a cycle is completed in approximately two minutes and during thisperiod, the sensors are no longer active.

The controller 259 is a micro-processor based device that includes thenecessary hardware, timer, software and memory for executing andperforming the various functions of the apparatus 30. As will bedescribed, the controller receives a number of electrical inputs fromcertain components and, depending upon the sequence of their receipt,generates electrical output signals to those components from which inputsignals were received and other components. The controller 259 receiveselectrical power from the power source 199 which may be either from anAC residential power supply, DC batteries or the like. The controller259 may receive a cycle input from a switch 261. Once energized, thecontroller is able to receive input from the weight sensing mechanism120, as well as an inboard limit switch 266 and an outboard limit switch268. And the controller 259 is then able to control operation of a motor204 which in turn operates the turntable as previously described. Themotor 204 also receives power from the power source 199. It will beappreciated that the motor 199 may receive power from a separate powersource that is of a different value or different format, than receivedby the controller. Or the controller 259 may directly supply power tothe motor that is stepped-up or stepped-down an appropriate amount.

Returning now to the operation of the apparatus, the controller 259includes an internal timer that is actuated upon exiting of the animal.Once this time has passed, the motor is energized and as a result threemovements are commenced by the controller 259—the litter pan 33 isrotated clockwise and counter-clockwise, the rake assembly 36 begins aslower rotation through the litter and litter pan 33, and the cover ofthe waste receptacle 37 is raised.

Following one-half completion of the cycle, where the scoop 174 hasdeposited litter clumps and solid waste matter into the receptacle 37,the inboard limit switch 266 is activated by the inwardly directed linkarm 264, from lower main driving shaft 196, which sends another signalto the controller to reverse rotation of the motor. As this occurs, therake assembly withdraws from the receptacle 37, the cover is closed andthe assembly moves down into the litter as it simultaneously rotatesback (counter-clockwise, as shown) to its parked position, with thescoop 174 submerged in the litter. Concurrently, the litter pan andturntable are also rotating in a clockwise direction, as shown. When theoutwardly directed cam 265 from the upper main driving shaft 181contacts outboard limit switch 266, a signal is sent to the controller.While the rake has almost returned to its parked position, the forwardmotion of a new cycle is commenced and run for approximately 2 seconds.The effect of this action is that the backlash is taken up from thegears of the drive mechanism and as a result, the rake is actually movedrearwardly the last remaining increment to its fully parked positionagainst or very near to the wall inner wall 161 of dust shield 42. Oncethe cycle is complete, all further movement ceases until either anothercycle is initiated by the pet or, the owner elects to cycle theapparatus manually by activating the switch 261 or similar controlswitch.

Another feature of the apparatus, which is programmed into thecontroller, is a motor overload circuit. During a cycle, should the rakeencounter an obstruction that the motor cannot overcome, the amperage tothe motor will increase until an overload switch signals the controllerto reverse the drive mechanism. Such switches, or overload protectors,are known in the art and do not constitute a limitation of theapparatus. Typically, a clump of solidified waste may have adhered tothe surface of the pan, perhaps due to low litter volume and the clumpmay have a mass that cannot be immediately moved by the rake. By designand programming, the rake will return to its parked position and inseveral seconds a new cycle will commence. Generally, a second pass atthe large clump or other obstruction is sufficient to remove or move itand the cycle continues. If not, a third park and re-initiation isprogrammed and if that attempt is still unsuccessful, the rake returnsto rest or park and the apparatus is shut-down. A red LED or similarindicator is activated by the controller to provide a visual signal tothe pet owner that the apparatus is unable to operate a cleaning cycle.The owner can then determine the nature of the problem and correct it sothat the cycle can then be performed. In this instance, it is likely theowner would then initiate a cycle manually, to view operation andconfirm that the previous problem no longer exists.

As noted hereinabove, an embodiment of the apparatus 30 is also withinthe scope of the invention which does not self-clean automatically, thatis, when the pet leaves the apparatus. To initiate self-cleaning, thepet owner decides when by pushing the button 261 or similar switch andthe apparatus proceeds to follow the cycle just described. Suchapparatus would not employ the sensing mechanism 120 and, because atiltable litter pan would not be required, the turntable could also beeliminated, in which instance the pan would be driven directly.

Thus, it should be evident that the apparatus and method of the presentinvention are effective for self-cleaning of litter devices, employingrotatable litter pans. Although the foregoing explanation has beendirected to the apparatus depicted in the drawings, it will beappreciated by those skilled in the art, that certain components couldbe varied or modified to obtain the same operation. One suchmodification envisioned is the combination of the turntable and litterpan into a single component, rather than two separate components.Another modification is in the sensing mechanism 120. As described inthe drawings, sensors are provided in the turntable and rails in thebase, so that contact can be made. However, the location could bereversed, by placing the rails or similar elements in the turntablewhich would be engageable with sensors from beneath. So long as thetilting of the pan provides a signal to the controller to activate thedrive mechanism, the relative position of the necessary components canbe varied to suit manufacturing as well as consumer preferences.

Based upon the foregoing disclosure, it should now be apparent that theuse of the litter apparatus described herein will carry out the objectsset forth hereinabove. It is, therefore, to be understood that anyvariations evident fall within the scope of the claimed invention andthus, the selection of specific component elements can be determinedwithout departing from the spirit of the invention herein disclosed anddescribed. Thus, the scope of the invention shall include allmodifications and variations that may fall within the scope of theattached claims.

1. A rake for a cat litter box for collecting clumped litter wastematerial from within the cat litter box, the rake comprising: a supportmember; a plurality of tines, each of said tines having a first end anda second end, said first end being connected to said support member;each of said plurality of tines including a first section extendingvertically from said support member to a generally perpendicular bendand a second section extending generally horizontally from said bend tosaid second end, said second sections of said plurality of tinesdisposed for receiving clumped litter waste material in a waste materialreceiving area; and at least one of said second sections of saidplurality of tines, including an upwardly curved portion, disposedbetween said bend and said second end and curved toward said supportmember for defining multiple regions of said second sections of saidplurality of tines within said waste material receiving area, such thatthe clumped litter waste material is contained in said multiple regionswhen the clumped litter waste material is collected from the cat litterbox.
 2. The rake of claim 1 wherein one of said second sections of saidplurality of tines includes said curved portion, and said tine iscentrally disposed among said plurality of tines.
 3. The rake of claim 1wherein one of said first sections of said plurality of tines includes aconstraint member for retaining clumped litter waste material within oneof said multiple regions of said waste material receiving area.